Orbital sander

ABSTRACT

An orbital sander ( 10 ) comprises a housing ( 14 ) and a drive unit ( 50 ) in the housing ( 14 ). The drive unit ( 50 ) includes an electric motor ( 58 ) and a drive shaft ( 68 ). The electric motor ( 58 ) has a motor output shaft defining a rotational axis ( 62 ). The drive shaft ( 68 ) is coupled for co-rotation with the motor output shaft about the rotational axis ( 62 ). The drive shaft ( 68 ) has an eccentric portion ( 70 ) configured to orbit about the rotational axis ( 62 ). A sanding pad ( 100 ) is coupled to the eccentric portion ( 70 ). A handle ( 16 ) extends from the housing ( 14 ) at an oblique angle greater than  90  degrees relative to the rotational axis ( 62 ). A battery pack ( 26 ) is coupled to the handle ( 16 ) for providing power to the electric motor ( 58 ). The orbital sander ( 10 ) is convenient for users to grasp.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to co-pending U.S. Provisional Patent Application No. 63/115,123 filed on Nov. 18, 2020, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a powered oscillating tool, and more particularly to an orbital sander, e.g., a battery powered direct drive orbital sander.

BACKGROUND

Orbital abrading machines generally include a manually manipulatable housing, a motor supported by the housing coupled to a drive shaft driven for rotation about a drive axis, and an assembly for mounting a pad for abrading a work surface for orbital movement about the drive axis. In random orbital abrading machines, the assembly can additionally mount the pad to an off axis bearing via an eccentric member that is fixed to the drive shaft of the motor, thereby defining a single eccentric orbit. Depending on the nature of this orbit, such an abrading machine can be used for coarse abrading work or for fine abrading work.

SUMMARY

In a particular embodiment of the present disclosure an orbital sander includes and includes a housing, a drive unit within the housing, the drive unit including an electric motor defining a rotational axis, a drive shaft configured to receive torque from the electric motor for rotating the drive shaft about the rotational axis, the drive shaft having an eccentric portion configured to orbit about the rotational axis, a sanding pad coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis, a handle extending from the housing at an oblique angle greater than 90 degrees relative to the rotational axis, and a battery pack coupled to the handle for providing power to the electric motor.

In another embodiment of the present disclosure, an orbital sander includes a housing, a drive unit within the housing, the drive unit including a drive shaft that is rotatable about a rotational axis and an eccentric portion configured to orbit about the rotational axis, a carrier coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis, a pad attachment coupled to and at least partially nested within the carrier, and a sanding pad coupled to the pad attachment for orbital motion therewith about the rotational axis.

In still another embodiment of the present disclosure, an orbital sander includes a housing, a drive unit within the housing, the drive unit including a drive shaft that is rotatable about a rotational axis and an eccentric portion configured to orbit about the rotational axis, a sanding pad coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis, and a dust extraction port directly connected to the sanding pad through which dust can be discharged away from the sanding pad.

In yet another embodiment of the present disclosure, an orbital sander includes a housing including attached first and second clamshell portions, a drive unit within the housing, the drive unit including a drive shaft that is rotatable about a rotational axis and an eccentric portion, a bearing positioned between the first and second clamshell portions for rotatably supporting the drive shaft, a carrier coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis, a torque absorber having a first end secured to the housing by first and second clamps corresponding, respectively, to the first and second clamshell portions of the housing, and a second end secured to the carrier, the torque absorber configured to restrict movement of the carrier to orbital motion about the rotational axis in response to rotation of the drive shaft, and a plurality of fasteners retaining the first and second clamps, and the first and second clamshell portions of the housing, as an assembled unit.

Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. Any feature(s) described herein in relation to one aspect or embodiment may be combined with any other feature(s) described herein in relation to any other aspect or embodiment as appropriate and applicable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an orbital sander in accordance with an embodiment of the present disclosure.

FIG. 2A is a side, cross-sectional view of the orbital sander of FIG. 1 .

FIG. 2B is an enlarged, cross-sectional view of a portion of the orbital sander of FIG. 1 .

FIG. 2C is a front, cross-sectional view of a portion of the orbital sander of FIG. 1 .

FIGS. 2D-2M are views of a counterweight in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIG. 3A is an enlarged perspective view of a portion of an orbital sander in accordance with another embodiment of the present disclosure.

FIG. 3B is an enlarged, cross-sectional view of the portion of the orbital sander shown in FIG. 3A.

FIGS. 4A-4B are enlarged, perspective views of a sanding pad in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIG. 4C is a front, cutaway view of a pad attachment to be used with the sanding pad of FIGS. 4A-4B.

FIG. 5A is a perspective view of a sanding pad in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1

FIG. 5B is a perspective view of a pad attachment in accordance with an embodiment of the present disclosure for use with the sanding pad of FIG. 4B.

FIGS. 6A-6C are sequential perspective views of the sanding pad of FIGS. 5A-5B mounted in a plurality of different orientations about a rotational axis in accordance with an embodiment of the present disclosure.

FIGS. 7A-7B are perspective and side cross-sectional views of a sanding pad in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIGS. 8A-8C are a series of enlarged views of a dust extraction system in accordance with an embodiment of the present disclosure to be used with the sanding pad of FIGS. 7A-7B.

FIG. 9 is a perspective, cross-sectional view of a sanding pad in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIG. 10A is a perspective view of a sanding pad in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIG. 10B is a side, cross-sectional view of the sanding pad of FIG. 10A.

FIG. 10C is a front, perspective view of a pad attachment to be used with the sanding pad of FIG. 10A.

FIG. 10D is a top, perspective view of the sanding pad of FIG. 10A with the pad attachment of FIG. 10C removed.

FIG. 11A is a perspective view of a sanding pad in accordance with an embodiment of the present disclosure for use with the sander of FIG. 1 .

FIG. 11B is a side, cross-sectional view of the sanding pad of FIG. 11A.

FIG. 11C is a front, perspective view of a pad attachment in accordance with an embodiment of the present disclosure to be used with the sanding pad of FIG. 11A.

FIG. 11D is a top, perspective view of the sanding pad of FIG. 10A with the pad attachment of FIG. 11C removed.

FIG. 12 is schematic diagram of a power control assembly in accordance with an embodiment of the present disclosure for use with the orbital sander of FIG. 1 .

FIG. 13 is a side view of an orbital sander in accordance with an embodiment of the present disclosure.

FIG. 14A is a side, cross-sectional view of an orbital sander in accordance with an embodiment of the present disclosure.

FIG. 14B is a top view of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 15A, 15B, 15C, and 15D are perspective and top views of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 16A-16B are side cross-sectional views of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 17A, 17B, 17C, and 17D are side cross-sectional views of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 17E-17F are perspective and top views of a controller in accordance with an embodiment of the present disclosure for use with an orbital sander.

FIG. 18A is a side, cross-sectional view of a fan in accordance with an embodiment of the present disclosure for use with an orbital sander.

FIG. 18B is a perspective cross-sectional view of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 18C-18D are side and bottom views of an orbital sander in accordance with an embodiment of the present disclosure.

FIG. 19 is a side cross-sectional view of an orbital sander in accordance with an embodiment of the present disclosure.

FIGS. 20A, 20B, and 20C are front, side, and perspective views, respectively, of a fan in accordance with an embodiment of the present disclosure for use with an orbital sander.

Before any embodiments of the present disclosure are explained in detail, it is to be understood that the embodiments described herein are not limited in scope or application to the details of construction and the arrangement of components set forth in the following description or as illustrated in the following drawings. The devices described herein are capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

Referring initially to FIGS. 1 and 2A, an orbital sander is illustrated and is generally designated 10. As shown, the orbital sander 10 may include a main housing 14 that may have a motor housing portion 18 for supporting a drive unit 50. The drive unit 50 may include an electric motor 58 that may have a drive shaft 68 that may extend along a rotational axis 62 configured to receive torque from the electric motor 58. During operation, the torque from the electric motor 58 may cause the drive shaft 68 to rotate.

As shown in FIG. 2A, the main housing 14 may further include a handle portion 16 that may extend from the motor housing 18 and may be graspable, or otherwise gripped, by the user of the sander 10 during use. In a particular embodiment, the handle portion 16 may extend from the motor housing 18 along a handle axis 63 at an angle, A1, with respect to the motor axis 62 that may extend through the motor housing portion 18. Further, in a particular embodiment, A1 may be an oblique angle that is greater than 90 degrees. For example, A1 may be greater than or equal to 91 degrees, greater than or equal to 92 degrees, greater than or equal to 93 degrees, greater than or equal to 94 degrees, or greater than or equal to 95 degrees. In another embodiment, A1 may be less than or equal to 105 degrees, such as less than or equal to 104 degrees, less than or equal to 103 degrees, less than or equal to 102 degrees, less than or equal to 101 degrees, less than or equal to 100 degrees, less than or equal to 99 degrees, less than or equal to 98 degrees, less than or equal 97 degrees, or less than or equal to 96 degrees. It is to be understood that A1 may be within a range between, and including, any of the minimum and maximum values of A1 disclosed herein.

As further shown in FIG. 2A, the handle portion 16 may include a controller 90 disposed therein. For example, the controller 90 may include a printed circuit board (PCB) that may have one or more microprocessors and multiple field-effect transducers for driving the motor 58. The handle portion 16 may also include a battery receptacle 22 for selectively receiving a battery pack 26 which may electrically power the electric motor 58 and the controller 90 when activated. The handle portion 16 may further include a trigger switch 32 disposed therein. The trigger switch 32 may be electrically operatively coupled to the controller 90 and may provide an input signal to the controller 90 to activate and deactivate the motor 58 in response to actuation of the trigger switch 32. As illustrated, a trigger 30 may protrudes from the handle portion 16. During operation, the trigger may be depressed by the user in order to actuate the trigger switch 32. It is to be understood that by having the handle portion 16 extend at an oblique angle, A1, from the motor housing 18, the user may be provided with an extra amount of ground clearance from a workpiece during use of the sander 10. This extra ground clearance may allow the user to install battery packs larger than the battery pack 26 illustrated in FIGS. 1 and 2A depending on the sanding operation.

As depicted in FIG. 2A, and FIG. 3B, the drive unit 50 may include a first bearing 72 that may support a first portion of the drive shaft 68. The first bearing 72 may be configured to be retained in the motor housing 18, i.e., the first bearing 72 may be engaged with the motor housing 18 in an interference fit. The drive unit 50 may also include a second bearing 75 that may support an upper portion of the drive shaft 68 within the motor housing 18. Additionally, as best shown in FIG. 3B, the drive unit 50 may include an eccentric bearing 74 that may support an eccentric carrier 66 on an eccentric portion 70 of the drive shaft 68. In an embodiment, the eccentric portion 70 of the drive shaft 68 may extend from a lower portion 69 of the drive shaft 68 adjacent to, or below, the first bearing 72. Further, in an embodiment, the eccentric portion 70 of the drive shaft 68 may be laterally offset from the motor axis 62 such that an offset axis 65 passing longitudinally through the eccentric portion 70 of the drive shaft 68 (parallel to the motor axis 62) may be spaced a distance, D, from the motor axis 62.

As shown in FIG. 3B, the drive shaft 68 may include a bore 86 and a screw 94 may be threadably engaged with the bore 86 in order to removably couple the eccentric carrier 66 to the eccentric portion 70 of the drive shaft 68. The bore 86 may be circumscribed by the eccentric bearing 74. The eccentric carrier 66 may fit over the eccentric bearing 74, as illustrated, and the screw 94 may securely fasten the eccentric carrier 66 to the eccentric portion 70 of the drive shaft. As such, when the drive shaft 68 rotates, the eccentric carrier may rotate with the drive shaft 68 about the rotational axis 62. FIG. 3B further indicates that an eccentric counterweight 73 may be positioned between the first bearing 72 and the eccentric bearing 74 on the drive shaft 68. The eccentric counterweight 73 may balance the rotational movement of the eccentric carrier 66 as the drive shaft 68 rotates. As illustrated, the eccentric carrier 66 may include a cylindrical bore 67 that may be configured to receive, and otherwise engage, a pad attachment 82. The bore 67 may not only help to control the concentric alignment of the pad attachment 82 and the carrier 66, but the bore 67 may also reduce the overall length of the sander 10, which can be advantageous when the user is trying to operate the sander 10 in confined spaces.

Referring to FIGS. 2D-2M, in some embodiments, the eccentric counterweight 73 can be a dual eccentric counterweight. The duel eccentric counterweight 73 can have dual mass counterweight as part of a two-piece construction. The two-piece construction can include a first counterweight part 73 a and a second counterweight part 73 b coupled together. The counterweight parts 73 a, 73 b may be coupled together using any combination of methods, for example, welding, adhesive bonding, mechanical fasteners, friction fit, etc. Similarly, the two counterweight parts 73 a, 73 b may be constructed from any combination of materials, either of the same material or different materials. For example, the counterweight parts 73 a, 73 b may be constructed from any combination of plastic, metal, alloys, etc.

In some embodiments, the counterweight parts 73 a, 73 b may be designed to provide both static and dynamic forces within a compact space internally within the sander 10. In one example, the first counterweight part 73 a can include multiple arms (e.g., three arms) to allow critical mass required to statically balance the eccentric components by shifting the center of gravity axially in a desired position, as shown in FIGS. 2F-2G. As shown in FIGS. 2D-2G and 2J-2M, the arms of the first counterweight part 73 a can include a substantially horizontal portion and a substantially vertical portion forming a substantially right-angled shape. A first end of the arms can be coupled to a cylindrical hub portion of the first counterweight part 73 a with the opposing ends of the arms coupled together via a half circle shape. The cylindrical hub portion can include an opening sized and shaped to receive the drive shaft 68 therethrough. When coupled to the drive shaft 68, via the hub, the drive shaft 68 can provide rotational force to the counterweight 73.

The second counterweight part 73 b can include a shape that provides an opposed mass to the first counterweight part 73 a and to provide a dynamic balance with the eccentric components, as shown in FIGS. 2D-2I. In one example, the second counterweight part 73 b can include a first convex shape coupled to a cylindrical hub portion. The cylindrical hub portion of the second counterweight part 73 b can be sized and shape to match the size and shape of the hub portion of the first counterweight part 73 a, include an opening sized and shaped to receive the drive shaft 68 therethrough. In some embodiments, the second counterweight part 73 b can include a keyway on or near the cylindrical hub portion to mate the second counterweight part 73 b with the first counterweight part 73 a such that the static (first counterweight part 73 a) and dynamic (second counterweight part 73 b) are opposed properly. The use of the key allows the first counterweight parts 73 a, 73 b to be eccentricity incorporated to form the counterweight 73 hub using a create poka-yoke assembly to ensure that the counterweight 73 is always positioned correctly relative to the eccentric components. Additionally, the counterweight 73 can be formed using double flat interior geometry to simplify assembly and eliminate orientation errors of joining the eccentric parts 73 a, 73 b.

Referring to FIGS. 2J-21 , the counterweight 73 can be sized and shaped to fit within a cavity within the motor housing 18. In some embodiments, the arms of the first counterweight part 73 a can be sized and shaped to extend away from the drive shaft 68 and shape around and substantially parallel to the carrier 66. In some embodiments, the counterweight 73 is supported on the carrier 66 located between two bearings 72, 74. The convex portion of the second counterweight part 73 b can extend away from the drive shaft 68 while remaining substantially over the top of the carrier. The second counterweight part 73 b may also include an offset portion extending toward the top of the carrier, as shown in FIG. 2K.

Referring now to FIG. 1 , FIG. 2B, FIG. 2C, and FIG. 3A, the orbital sander 10 may include a plurality of clamps 34 that may be secured on opposite sides of the motor housing portion 18 by fasteners 36 (FIG. 2C and FIG. 3A) to obtain a flush profile with the exterior of the motor housing 18. The clamps 34 may be configured to impart a clamping force onto a portion of the drive unit 50. Specifically, the fasteners 36 may extend through the motor housing 18 to connect two housing clamshells 13, 15 that make up the housing 14 of the orbital sander 10. This relationship imparts a clamping force onto the first bearing 72 to clamp the bearing 72 between the two housing clamshells 13, 15. In addition, the clamps 34 may be configured to retain a first end 39 of a torque absorber 38 on the motor housing 18. The torque absorber 38 may be configured to flex and absorb the torque from the motor 58 to prevent the eccentric carrier 66 from free rotation about the motor axis 62. A shown, the torque absorber 38 may further includes a second end 41 mounted to the carrier 66 for limiting the movement of the carrier 66 to orbital motion about the motor axis 62 in response to rotation of the drive shaft 68.

With reference to FIGS. 2A-2B, in some embodiments, the eccentric carrier 66 may include an axial locating face 71 adjacent to the cylindrical bore 67. The cylindrical bore 67 can guide the user to easily mount and partially nest the pad attachment 82 within the bore 67 of the carrier 66. In an embodiment, as shown in FIG. 2B, the pad attachment 82 may be fixed to the carrier 66 by a plurality of screws 78 that may extend through a plurality of mounting holes 124 (FIG. 4C) on the pad attachment 82 and that may be threaded to correspond to threaded apertures 77 in the axial locating face 71 of the carrier 66. During operation, the axial locating face 71 can aid in the alignment of the pad attachment 82 and the carrier 66 to facilitate proper insertion and equal loading of the screws 78. Further, as the carrier 66 rotates, the pad attachment 82 ma also rotate.

In a particular embodiment, to ensure proper alignment and equal torqueing of the screws 78, the eccentric carrier 66 may further include a flange 81. The flange 81 may help clamp the second end 41 of the torque absorber 38 between an inner annular surface 83 of the pad attachment 82 and the axial locating face 71 of the carrier 66. This may prevent any undesired imbalances of the pad attachment 82 and an attached sanding pad 100. Moreover, by using this clamping arrangement, the annular surface 83 and the axial locating face 71 may compress the second end 41 of the torque absorber 38 therebetween to form a hard stop in order to substantially ensure that the annular surface 83 is uniformly abutted with the axial locating face 71 about the periphery thereof. This arrangement may also maintain concentricity between the mounting holes 124 and the carrier 66 (with the cylindrical bore 67).

As illustrated in FIG. 2B, the second end 41 of the torque absorber 38 may compressed between the flange 81 and the inner annular surface 83 of the pad attachment 82 to a sufficient thickness that may cause the axial locating face 71 to form a hard stop against which the inner annular face 83 of the pad attachment 82 may be abutted when the screws 78 are fully seated within the carrier 66. Accordingly, the screws 78 may be installed and torqued into place without any concern for a non-uniform clamping load being applied to the second end 41 of the torque absorber 38. Therefore, the tolerance for applying torque to the screws 78 during the manufacturing process for the sander 10 may be substantially increased, thereby reducing assembly time and associated cost. Furthermore, accurately mounting the screws 78 in their respective mounting holes 124 may substantially reduce the possibility of one of the screws 78 being torqued to a lesser or greater degree. In turn, the pad attachment 82 may be less susceptible to unwanted forces that may be applied thereto from unevenly torqued screws 78. Reducing unevenly distributed forces on the pad attachment may substantially reduce any undesirable vibration of the pad attachment 82 and connected sanding pad 100 during use.

FIGS. 1 and 2A further show that the orbital sander 10 may include a sanding pad 100 affixed, or otherwise coupled to the pad attachment 82. Details concerning the construction of the sanding pad 100 are illustrated in FIGS. 4A through 4C. Referring briefly to FIG. 1 , the sanding pad 100 may include a main body 116 having a bottom surface 140. A sanding sheet (not shown) may be attached to the bottom surface 140 of the sanding pad 100 and may be used to sand a workpiece during operation of the orbital sander 10. FIG. 4B shows that the sanding pad 100 may include a connection portion 114 that may extend upward from the main body 116 in direction that is substantially opposite to the lower surface 140 of the sanding pad 100 (FIG. 1 ). The connection portion 114 may include a locking geometry 110 that may be configured to engage the pad attachment 82 to axially affix the sanding pad 100 to the pad attachment 82 for orbital motion therewith. As shown in FIG. 2B, the pad attachment 82 may include a projection portion 120 that may be configured to be received in the cylindrical bore 67 of the eccentric carrier 66 (FIG. 3B). The pad attachment 82 may also include a mating locking geometry 190 radially disposed about an interior of the attachment 82. Further, the pad attachment may include a plurality of mounting holes 124 radially positioned about the pad attachment 82 for mounting the pad attachment 82 to the torque absorber 38.

As illustrated in FIG. 4A, the locking geometry 110 of the sanding pad 100 may include a plurality of rigid tabs 108 that may extend in a direction that is radially outward from a radially outward facing surface of the connection portion 114. As such, the connection portion 114 may be configured to be inserted into the projection portion 120 and rotated into engagement with the mating locking geometry 190 of the pad attachment 82. A foam spring 112 may be positioned on a top surface of the main body 116 surrounding the connection portion 114. The foam spring 112 may be configured to bias the sanding pad 100 away from the pad attachment 82 in order to maintain the rigid tabs 108 in place with locking geometry 190 of the pad attachment 82.

Referring now to FIGS. 4B and 4C, the pad attachment 82 may further include a wave spring 192 that may be disposed within the projection 120 of the pad attachment 82. The wave spring 192 may be configured to bias the rigid tabs 108 into axial engagement with the mating locking geometry 190 of the pad attachment 82. This arrangement, or configuration, may allow the rigid tabs 108 to be rotatably and axially constrained within the mating locking geometry 190 due to the combination of the spring forces between the foam spring 112 and the wave spring 192. The foam spring 112 may impart a force onto the locking geometry 110 of the sanding pad 100 against the bias of the wave spring 192, which may force the tabs 108 into engagement with the mating locking geometry 190. This engagement may substantially prevent unwanted vibration or chattering between the sanding pad 100 and the pad attachment 82.

FIGS. 5A and 5B illustrate a sanding pad 200 in accordance with another embodiment of the sander 10. It is to be understood that like components and features of the sanding pad 100 of FIGS. 4A and 4B will be used plus “100”. The sanding pad 200 includes a main body 216 having a bottom surface 140 (see, FIG. 1 ) to which a sanding sheet may be attached for performing sanding operations on a workpiece during operation of the orbital sander 10. Further, the sanding pad 200 may include a connection portion 214 that may extend upward from the main body 216 in a direction that is substantially opposite to the lower surface 140. As depicted in FIGS. 5A and 5B, the connection portion 214 may include a locking geometry 210 that may be configured to engage a pad attachment 182 in order to affix the sanding pad 200 to the pad attachment 182 for orbital motion therewith. The pad attachment 182 may include a projection portion 220 configured to be received within the cylindrical bore 67 of the eccentric carrier 66. The pad attachment 182 may further include a plurality of groove portions 228 that may be radially spaced about an interior of the projection portion 220. Moreover, the pad attachment 182 may include a plurality of snap-fit portions 232 that may be radially spaced about the interior of the projection portion 220. The snap-fit portions 232 may alternate between the plurality of groove portions 228. As shown in FIG. 5B, the pad attachment 182 may also include a plurality of mounting holes 224 that may be radially disposed around the projection portion 220 of the pad attachment 182. The mounting holes 224 may be used to mount the pad attachment 182 to the torque absorber 38. In a particular embodiment, the locking geometry 210 of the sanding pad 200 may include a plurality of flexible tabs 204 extending from a top surface of the main body 216 and a plurality of rigid tabs 208 extending from a radially outward facing surface of the connection portion 214. The flexible tabs 204 and the rigid tabs 208 may be configured to be inserted into the projection portion 220 of the pad attachment 182. A foam spring 212 may be disposed on the top surface of the main body 216 of the sanding pad. Specifically, the foam spring 212 may circumscribe the connection portion 214 and locking geometry 210 of the sanding pad 200. The foam spring 212 may be configured to bias the sanding pad 200 into engagement with the pad attachment 82. This configuration may substantially reduce, or prevent, unwanted vibration or chattering between the sanding pad 200 and the pad attachment 182 during operation of the orbital sander 10.

With continued reference to FIGS. 5A and 5B, as the sanding pad 200 is fastened to the pad attachment 182, the plurality of rigid tabs 208 may be configured to be received within the plurality of groove portions 228 in the projection portion 220. Also, the plurality of flexible tabs 204 may be configured to snap-fit into the plurality of snap-fit portions 232 within the projection portion 220. The plurality of rigid tabs 208 can provide extra strength to the locking geometry 210 of the sanding pad 200 in case of heavy loading or scenarios where the sanding pad 200 is dropped onto a hard surface. Since the locking geometry 210 of the sanding pad 200 and the corresponding groove portions 228 and snap-fit portions 232 of the projection portion 220 are radially symmetrical, the locking geometry 210 of the sanding pad 200 can engage with the pad attachment 182 so that the sanding pad 200 can be installed at a plurality of different rotational positions relative to the orbital sander 10.

For example, as illustrated in FIGS. 6A through 6C, the sanding pad 200 may installed on the orbital sander 10 in a variety of different angular positions relative to the orbital sander 10. FIG. 6A shows that the sanding pad 200 may be mounted on the orbital sander 10 so that a longitudinal axis of the sanding pad 200 is parallel to the handle axis 63 of the orbital sander 10. Additionally, FIG. 6B shows that the sanding pad 200 may be mounted on the orbital sander 10 so that the longitudinal axis of the sanding pad 200 forms an angle, e.g., 45 degrees, with respect to the handle axis 63. Finally, FIG. 6C shows that the sanding pad 200 may be mounted on the orbital sander 10 so that the longitudinal axis of the sanding pad 200 is substantially perpendicular to the handle axis 63 of the orbital sander 10.

FIGS. 7A and 7B illustrate a sanding pad 300 in accordance with another embodiment of the sander 10. It is to be understood that like components and features of the sanding pad 100 of FIGS. 4A-4B will be used plus “200”. The sanding pad 300 includes a main body 316 having a bottom surface 340 to which a sanding sheet may be attached for performing sanding operations on a workpiece during operation of the orbital sander 10. The sanding pad 300 may include a connection portion 314 that may extend upward from the main body 316 in a direction that is substantially opposite to the lower surface 340. The connection portion 314 may include a locking geometry 310 that may be configured to engage the pad attachment 182 in order to affix the sanding pad 300 to the pad attachment 182 for orbital motion therewith.

Similar to the sanding pad 200 shown in FIGS. 4A and 4B, the locking geometry 310 of the sanding pad 300 may include a plurality of flexible tabs 304 that may extend from a top surface of the main body 316. The locking geometry 310 of the sanding pad 300 may also include a plurality of rigid tabs 308 that may extend radially outward from a radially outward facing surface of the connection portion 314. The connection portion 314 may be configured to be inserted into the projection portion 220 of the pad attachment 182. As illustrated in FIG. 7A, the sanding pad 300 may further include a foam spring 312 on the top surface of the main body 316 surrounding the connection portion 314. The foam spring 312 may be configured to bias the sanding pad 300 into engagement with the pad attachment 182. It is to be understood that the locking geometry 310 of the sanding pad 300 may removably engaged with the pad attachment 182 in a similar fashion to the locking geometry 210 of the sanding pad 200 as detailed above.

Referring now to FIGS. 7A and 7B and FIGS. 8A through 8C, the sanding pad 300 may further include a dust outlet 325 that may be provided at the rear of the body 316. A dust extraction port 332 may fluidly connected to the dust outlet 325. Further, as shown, a plurality of suction holes 320 may extend through the body 316 of the sanding pad 300 into an internal cavity 330. In an embodiment, the dust extraction port 332 may include a snap-fit coupling 347 that may be received within the dust outlet 325 for axially retaining the dust extraction port 332 to the dust outlet 325. The snap-fit coupling 347 may also permit the dust extraction port 332 to be removed from the dust outlet 325, and the sanding pad 300, without the use of tools.

As depicted in FIG. 8B, the sanding pad 300 may include a detent system 351 that may allow the dust extraction port 332 to be repositionable within the dust outlet 325 in a plurality of different rotational positions relative to the sanding pad 100. As illustrated, the detent system 351 may include a single detent 352 formed on the sanding pad 300 and a plurality of detent recesses 353 formed in the snap-fit coupling 347 in which the detent 352 is alternately receivable to hold the port 332 in a desired rotational position. Specifically, the snap-fit coupling 347 may include a plurality of tines 348 extending axially along the length of the snap-fit coupling 347. Each tine 348 may include a tooth 349 that may extend radially outward from a distal end of each tine 348. Further, the tooth 349 of each tine 348 of the snap-fit coupling may be formed with a respective detent recess 353. The detent system 351 may allow the user to reorient the dust extraction port 332 to a variety of directions relative to the sanding pad 300 in order to facilitate the use the orbital sander 10 in tight spaces. It is to be understood that the dust extraction port 332 may be connected to a dust bag, a container, or a vacuum hose in order to collect and/or transport dust and other debris away from the sanding pad 300.

With reference to FIGS. 7A-7B, in some embodiments, the sanding pad 300 may further include one or more counterweights 336 in order to shift a location of a center of gravity 350 of the sanding pad 300 from a position that is adjacent to the dust outlet 325 to a position that is substantially aligned, or co-axial, with a central axis 355 of the connection portion 314 when the dust extraction port 332 is attached, or otherwise fluidly coupled, to the sanding pad 300. It is to be understood that the shift in the center of gravity 350 due to the placement of the counterweight 336 is illustrated by arrow 337 in FIG. 7B. In a particular embodiment, unwanted vibration or chattering between the sanding pad 300 and the pad attachment may be substantially minimized, or reduced, by shifting the center of gravity 350 of the sanding pad 300 from the position near the dust outlet to the position aligned with the connection portion 314, as shown. Further, it is to be understood that the counterweight 336 may be removable.

FIG. 9 illustrates a sanding pad 400 in accordance with another embodiment of the sander 10. It is to be understood that like components and features of the sanding pad 100 of FIGS. 4A through 4B will be used plus “300”. The sanding pad 400 may be relatively smaller than conventional, larger sanding pads to allow the user to fit the sanding pad 400 into tight spaces. The smaller size of these sanding pads 400 can cause unwanted vibration between the sanding pad 400 and the sander 10. To solve this issue, the sanding pad 400 may include a multi-piece main body 416 and a steel plate ballast 460 integrated within the main body 416. The ballast 460 can increase the mass of the sanding pad 400 to provide the pad 400 with the same mass as a conventional, larger sanding pad to reduce any unwanted vibration between the smaller sanding pad 400 and the sander 10 during use.

In some embodiments of the sanding pad 400, similar to the sanding pad 200 in FIGS. 4A through 4B, the sanding pad 400 can include a main body 416 having a bottom surface 440 to which a sanding sheet may be attached for performing sanding operations on a workpiece. As shown, a connection portion 414 may extend upward from the main body 416 in a direction that is substantially opposite to the lower surface 440. The connection portion 414 may include a locking geometry 410 that may be configured to engage the pad attachment 182 in order to affix the sanding pad 400 to the pad attachment 182 for orbital motion therewith. The locking geometry 410 may include a plurality of flexible tabs 404 that may extend from a top surface of the main body 416 and a plurality of rigid tabs 408 that may extend radially outward from a radially outward facing surface of the connection portion 414. The connection portion 414 may be configured to be inserted into the projection portion 220 of the pad attachment 182. In a particular embodiment, the locking geometry 410 of the sanding pad 400 may fasten to the pad attachment 182 in a similar fashion as the locking geometry 210 of the sanding pad 200 as detailed above. In some embodiments of the sanding pad 400, the sanding pad 400 can include a plurality of counterweights 436 that may be coupled to, or otherwise integrated into, the top surface of the main body 416. The counterweights 346 may further balance the pad 400 and substantially minimize, or reduce, vibration of the pad 400 during use.

Referring now to FIGS. 10A through 10D, a sanding pad for use with the orbital sander 10, in accordance with another embodiment, is shown and is generally designated 500. It is to be understood that like components and features of the sanding pad 100 of FIGS. 4A through 4B will be used plus “400”. The sanding pad 500 may include a main body 516 that may have a bottom surface 540 to which a sanding sheet (not shown) may be attached for performing sanding operations on a workpiece during operation of the orbital sander 10.

As shown in FIGS. 10B and 10D, the sanding pad 500 may include a connection portion 514 (FIG. 10D) that may extend upward from the main body 516 in a direction that is substantially opposite to the lower surface 540. The connection portion 514 may include a locking geometry 510 that may be configured to engage a pad attachment 511 in order to axially affix the sanding pad 500 to the pad attachment 511 for orbital motion therewith. The pad attachment 511 may include a projection portion 520 that may be received within the cylindrical bore 67 of the eccentric carrier 66 of the orbital sander 10. As depicted in FIG. 10C, the pad attachment 511 may also include a recessed portion 521 on the interior of the projection portion 520. Further, as shown in FIG. 10C, the pad attachment 511 may include a threaded projection 574 that may extend from the interior of recessed portion 521. The threaded projection 574 may be formed with internal threads 575. FIG. 10C also shows that the pad attachment 511 may further include a plurality of angled side walls 563 that may partially define the recessed portion 521 and a plurality of mounting holes 524 that may be radially disposed about the pad attachment 511. The mounting holes 524 may be used to mount the attachment 511 to the torque absorber 38 of the orbital sander 10.

FIG. 10D shows that the locking geometry 510 of the sanding pad 500 may be configured as a hexagonal post 564 that may extend from the top of the main body 516. The locking geometry 510 of the sanding pad 500 may be sized and shaped to be received within the recessed portion 521 of the pad attachment 511. As shown in FIG. 10B, the locking geometry 510 may further include a through-hole 515 that may be located in the center of the hexagonal post 564. In a particular embodiment, the through-hole 515 may extend through the connection portion 514 and into a screw mounting hole 517 formed in the body 516 of the sanding pad 500. In order to fasten the sanding pad 500 to the pad attachment 511, as depicted in FIG. 10B, a user may insert the hexagonal post 564 into the recessed portion 521 of the pad attachment 511 to mate the hexagonal post 564 with the plurality of angled side walls 563. Once the post 564 is seated within the recessed portion 521, the user can thread a mounting screw 580 through the mounting hole 517 in the bottom of the sanding pad 500 and into the threaded projection 574 of the pad attachment 511 in order to engage the internal threads 575 and threadably couple the sanding pad 500 to the pad attachment 511. To mount the sanding pad 500 to the pad attachment 511 at a different rotational position, the user can re-position the hexagonal post 564 to a different orientation within the recessed portion 521 of the pad attachment 511.

FIGS. 11A through 11D illustrate a sanding pad 600 for the orbital sander 10 in accordance with another embodiment of the sander 10. It is to be understood that like components and features of the sanding pad 100 of FIGS. 4A through 4B will be used plus “500”. As depicted, the sanding pad 600 may include a main body 616 having a bottom surface 640 to which a sanding sheet may be attached for performing sanding operations on a workpiece. FIG. 11D shows that the sanding pad 600 may include a connection portion 614 that may extend upward from the main body 616 in a direction that is substantially opposite to the lower surface 640. As further shown in FIG. 11D, the connection portion 614 may include a locking geometry 610 that may be configured to engage a pad attachment 611 in order to affix the sanding pad 600 to the pad attachment 611 for orbital motion therewith.

FIG. 11D further depicts a foam spring 612 that may be positioned on a top surface of the main body 616 circumscribing the connection portion 614. In a particular embodiment, the foam spring 612 may be configured to bias the sanding pad 600 into engagement with the pad attachment 611. As shown in FIG. 11C, the pad attachment 611 may include a projection portion 620 that may be received in the cylindrical bore 67 of the eccentric carrier 66 of the orbital sander 10. The pad attachment 611 may also include a recessed portion 621 on the interior of the projection portion 520. A post 677 may extend from the interior of the recessed portion 521.

As indicated in FIG. 11B, the post 677 may be formed with an internal chamber 681 that is sized and shaped to receive a permanent magnet 683 therein. The pad attachment 611 may further includes a plurality of angled side walls 663 that may at least partially define the recessed portion 621 and a plurality of mounting holes 624 radially disposed around the pad attachment 611 that may be used to mount the attachment 611 to the torque absorber 38. FIG. 11D shows that the locking geometry 610 of the sanding pad 600 may be configured as a hexagonal post 664 that may extend from the top of the main body 616. The locking geometry 610 of the sanding pad 600 may be received within the recessed portion 621 formed in the pad attachment 611. The locking geometry 610 of the sanding pad 600 fits into the pad attachment 611 in the same fashion as the locking geometry 510 of the sanding pad 500 as detailed above.

With continued reference to FIGS. 11A through 11D, the sanding pad 600 may further include a steel insert 684 mounted within the body 616 between the bottom surface 640 of the sanding pad 600 and the connection portion 614. In a particular embodiment, the steel insert 684 may facilitate a magnetic coupling between the sanding pad 600 and the pad attachment 611 when the pad 600 is fastened to the attachment 611. During use, in order to fasten the sanding pad 600 to the pad attachment 611, a user may insert the hexagonal post 664 into the recessed portion 621 of the pad attachment 611 in order to mate, or otherwise engage, the hexagonal post 664 with the plurality of angled side walls 663. Once the hexagonal post 664 is seated within the recessed portion 521, the permanent magnet 683 may attract the steel insert 684 within the body 616 of the sanding pad 600 to magnetically latch the sanding pad 600 to the pad attachment 611. To mount the sanding pad 600 to the pad attachment 611 at a different rotational position, the user can re-position the hexagonal post 664 to a different orientation within the recessed portion 621 of the pad attachment 611.

Referring now to FIG. 12 a schematic diagram of a power control assembly 128 is illustrated. As shown, the power control assembly may include the trigger 30, described above. In some embodiments, the trigger 30 may include, or may be otherwise coupled to, a lock-on button 130 to fix an actuation of the trigger 30. For example, a user may depress the trigger 30 to activate the sander 10 and then depress the lock-on button 130 to fix the trigger 30 into the depressed activated position. The lock-on button 130 can lock the trigger 30 in place using any combination of mechanisms. In some embodiments, trigger 30 and/or the trigger switch 32 can include or otherwise be coupled to a variable speed control 132. The variable speed control 132 can be provided to modify a speed of the motor 58, for example, via an input signal to the controller 90. The unique combination of the trigger 30, the lock-on button 130, and the variable speed control 132 provides simplified operating controls enabling a user to lock the trigger and cycle speed modes at their convenience. As shown, the variable speed control 132 and the trigger 30 may be operably coupled to an electronic controller 139. The electronic controller 139 may work in conjunction with the variable speed control 132 and the trigger 30 to control the operation and speed of the orbital sander 10.

In some embodiments, the variable speed control 132 can include a plurality of speed selections that are adjustable while avoiding resonating frequencies of the sander 10 or its components to offer a low vibration operation. The speeds are selected such that any vibration caused by the sander 10 will not be sufficient to disengage the lock on button 130 when it is engaged. For example, the variable speed control 132 can include four speed selections of 8000 rotations per minute (RPM), 10,000 RPM, 12,000 RPM, and 14,000 RPM.

Referring to FIG. 13 , in some embodiments, the orbital sander 10 can be sized and shaped to provide improved operation of the tool in open or confined spaces. The orbital sander 10 can include the motor housing 18 and the handle portion 16 as discussed with respect to FIGS. 1 through 2A. The orbital sander 10 can include a compact housing 14 design that has a height that allows users to access tight spaces, for example, within areas of furniture, cabinetry, shelving, etc. For example, the overall height, H, of the motor housing 18 of the sander 10 can be approximately 110 mm-120 mm. It is to be understood that H may be measured between a lower plane, P_(L), passing through the lowermost point of the orbital sander 10, e.g., at the bottom of the sanding pad 100, and an upper plane, P_(U), passing through the uppermost point of the orbital sander 10. The compact height of the motor housing 18 also allows a user to have their hands close to the work surface, for example, to improve control and feel. Similarly, the location of the trigger 30 provides users plenty of clearance to work surface while keeping user's hand close to the work surface. For example, a distance, T, of the trigger to the work surface, measured from a work surface plane, P_(W), at the work surface to a trigger plane, P_(T), at the base of the trigger can be approximately 40 mm-60 mm. In some embodiments, the length of travel for the trigger 30 can be designed such that it provides user comfort when holding the handle portion 16 and pulling the trigger 30. For example, the travel distance, D, for the trigger 30 can be about one to two (1-2) finger widths 17. Having this travel distance for the trigger, for example, may provide the user the flexibility to hold the orbital sander 10 in multiple positions and tool orientations while being able to engage the variable speed trigger 30 with multiple different fingers. Additionally, a handle angle, A_(H), between a longitudinal axis of the handle portion 16 and/or trigger 30 and a longitudinal axis, A, of the motor housing 18 can be approximately ninety-five degrees (95°). The handle angle, A_(H), may provide for a comfortable grip as well as effective use of the tool.

In some embodiments, the handle portion 16 of the orbital sander 10 can be sized and shaped to provide a user with a comfortable gripping surface close to a central axis, A, of the pad. For example, the handle portion 16 can have a length that is sufficient to enable the user to grip the handle portion 16 connected to the motor housing 18 rather than having to position their hand over the motor housing 18. The orbital sander 10 can include any combination of measurements and ratios to achieve such functionality. In one non-limiting example, the length, X, of the orbital sander 10 can be approximately 220 mm-240 mm. X may be measured from a foremost plane, P_(F), passing through the foremost part of the sanding pad 100 to an interface plane, P_(I), passing through the far end of the handle portion 16 at the interface of the handle portion 16 and the battery pack 26. A length, Y, from a front motor housing plane, P_(F), passing through the front of the motor housing 18 of the orbital sander 10 to the interface plane, P_(I), passing through the end of the handle portion 16, i.e., at the interface of the handle portion 16 and the battery pack 26, can be approximately 190 mm-210 mm. Finally, a length, Z, between the interface plane passing through the end of the handle portion 16, i.e., at the interface of the handle portion 16 and the battery pack 26, and a central plane passing through the central axis, A, of the motor housing 18 of the orbital sander 10 can be approximately 160 mm-190 mm.

Referring to FIGS. 14A-14B, in some embodiments, the orbital sander 10 (with the battery pack 26 installed therein) can be designed such that it has a center of gravity proximate to the user gripping area. For example, the center of gravity (CG) can be situated above the trigger 30 as shown in the side view of FIG. 14A and along a center plane of the sander 10 as shown in the above view of FIG. 14B. In this configuration, the pivot point of the sander 10 is situated substantially above the trigger 30. Designing the sander 10 to have a center of gravity CG at this location will reduce user fatigue by balancing the weight of the sander 10 and battery pack 26 around the gripping area in the hand of the user. Because the center of gravity CG is centrally located about the user grip area, this balance can be provided in various orientations as well. For example, the center of gravity (CG) may be centered around the primary gripping area, pistol grip style with index finger and thumb wrapped around the handle. The center of gravity CG can be established using any combination of methods. For example, the components of the sander 10 can be situated within the housing such that they balance the weight of the device to establish the center of gravity CF as a pivot point. Similarly, the sander 10 can include attached and/or integrated counterbalances to create the desired center of gravity CF.

Referring now to FIGS. 15A through 15D, in some embodiments, the motor housing 18 can include a work light 134, for example, one or more light emitting diodes (LEDs). The work light 134 can be used to illuminate the work surface in front of the sander 10 as well as an inspection light. For example, the work light 134 can activate in response to activation of the trigger 30 but it can remain on for a predetermined period of time (e.g., 5 to 20 seconds) thereafter to allow a user to inspect the work surface without vibration caused by operation of the sander. The work light 134 can be mounted at a location on the motor housing 18 of the sander 10 at an angle to provide illumination to a front end of the sander 10 (e.g., tip of the sanding pad 200) as well as the work surface, as depicted in FIG. 15D.

In a particular embodiment, the work light 134 may be placed such that it can provide sufficient illumination while maintaining low profile on the motor housing 18 of the sander 10 such that it can fit tool into tight spaces. For example, the work light 134 can be mounted within the motor housing 18, adjacent to a top of the motor housing 18 at the front of the motor housing 18, while protruding slightly at a housing angle A_(H) with respect to the rotational axis 62 of the motor 58. In a particular embodiment, the housing angle A_(H) may be about fifteen degrees (15°). Having the work light 134 situated in this manner can substantially minimize the amount that the work light 134 protrudes from the motor housing 18 while allowing it to provide sufficient illumination (illustrated by illumination area A_(I) in FIG. 15D) on a work surface. For example, as shown in FIG. 15D, the work light 134 can illuminate a large wide area in front of the sander 10, including the tip of the sander (e.g., sanding pad 200). In particular, the sanding pad 100 may have a sanding pad surface area A_(SP) and the illumination area A_(I) may be approximately six (6) times greater than the sanding pad surface area A_(SP).

In a particular embodiment, the work light 134 may direct light to the workpiece in front of the orbital sander 10 at a beam angle A_(B), as measured from the rotational axis 62 of the motor 58 (FIG. 15B). In a particular embodiment, the beam angle A_(B) may be about thirty-five degrees (35°). It is to be understood that the work light 134 may illuminate the surface of the workpiece during use and the work light 134 may remain on for a period of time, e.g., ten seconds, twenty seconds, thirty seconds, etc., after the trigger switch 32 of the orbital sander 10 is released. This may allow the work light to also be used as an inspection light.

Referring to FIGS. 16A and 16B, in some embodiments, the sander 10 can include battery terminals 136 located between respective planes coinciding with the axial length of the stator 138. In one example, as shown in FIG. 16A, the battery terminals 136 can be located between parallel planes (P1, P2) established by both ends of the stator 138 while being parallel with a work surface. For example, as shown in FIG. 16A, P1 may be established by the back of the stator 138 and P2 may be established by the front of the stator 138. Both P1 and P2 may be substantially parallel to the work surface. The battery terminals 136 may be situated between P1 and P2. In another example, as shown in FIG. 16B, the battery terminals 136 can be located between parallel planes (P1, P2) coinciding with the opposite ends of the stator 138 while P1 and P2 may be parallel with the handle portion 16. For example, as shown in FIG. 16B, P1 is established by the back of the stator 138 and P2 is established by the front of the state with both P1 and P2 being parallel to a central axis, A2, of the handle portion 16. The battery terminals 136 may be situated between P1 and P2. Having the battery terminals 136 positioned within the handle portion 16 in this manner may provide low profile of the handle portion 16 with respect to work surface, while maintaining battery pack 26 clearance with the surface of the workpiece. This configuration will contribute to the sander 10 being able to be used in tight spaces.

In another aspect, the one or more battery terminals may be situated within the handle portion and located between respective planes coinciding with opposite ends of the stator 138. The planes may be parallel to the sanding pad. Further, the planes may be parallel to a longitudinal axis of the handle portion.

Referring to FIGS. 17A through 17F, in some embodiments, the controller 90 can be sized and shaped to fit within the housing 14 and/or handle portion 16 while maintaining the desired size and shape of the sander 10. The controller 90 can also positioned within the handle portion 16 at a desired orientation to ensure that the printed circuit board (PCB) of the controller 90 is sufficiently sized to include all the necessary components while maintaining a fit within the handle portion 16. For example, the controller 90 can be positioned within the handle portion 16 at a controller angle, A_(C), 35° with respect to a central axis A of the stator 138 and/or shaft, as depicted in FIG. 17A.

In some embodiments, the controller 90 can be sized and shaped to fit within a contour of the handle portion 16. For example, the controller 90 may be a generally oblong, or egg-shaped, PCB that may be sized and shaped to match the contour of the inner surface of the substantially cylindrical housing. The controller 90 can be provided with any combination of shapes depending on the shape of the housing. For example, the controller 90 can be a polynomial shape if the housing is not a rounded shape. Using a controller 90 that is sized, shaped, and oriented within the housing 14 as disclose herein may provide a distinct advantage to substantially maximize the space required for all the electrical components on a single PCB of the controller 90 while being able to be aligned at an angle within the handle portion 16 to provide a comfortable gripping surface that defines the handle portion 16 shape.

Referring to FIGS. 17C through 17F, in some embodiments, the controller 90 can be designed such that it can only be installed in one direction/orientation, i.e., in a single direction and a single orientation. The combination of the handle portion 16 shape, its mounting components, and the controller 90 shape can work in combination for a poka-yoke design that nests into the handle portion 16 such that the controller 90 may be limited to being installed in one direction relative to the handle portion 16 in order to prevent rotation without a mechanical fastener or locking features. The dimensions of the PCB for the controller 90 can vary depending on the internal dimensions of the handle portion 16. For example, the PCB can be about 30-40 mm wide by 50-60 mm high in order to nest firmly within the interior of the handle portion 16, as shown in FIGS. 17C through 17D. The controller 90 can be mounted within the housing 14 and/or handle portion 16 using any combination of methods. For example, the controller 90 can be mounted via friction fit tabs (e.g., as shown in FIG. 17C), using adhesive, using fasteners, or a combination thereof.

Referring to FIGS. 18A through 18D, in some embodiments, the sander 10 can include a rotor fan 142 coupled to the drive shaft 68 to co-rotate therewith and induce a cooling airflow throughout the housing 14. In a particular embodiment, due to its placement and configuration as a centrifugal fan, the rotor fan 142 may induce separate airflows AF1, AF2 within the housing 14 flowing in opposite directions. The rotor fan 142 may induce airflows upstream of the fan that are directed axially away from the fan. Exhaust airflow may be discharged in a radial direction through exhaust vents in the housing 14. As illustrated in FIG. 18B, the rotor fan 142 may be situated at a central location within the housing 14 to circulate air through both ends of the housing 14. For example, the rotor fan 142 can be positioned on the drive shaft 68 between the motor 58 and the eccentric components, such as the bearing 74, carrier 66, and/or counterweight 73. In some embodiments, the housing 14 can include a plurality of air intake vents for pulling air into the housing 14 and air exhaust vents for discharging air from the housing 14 to create a circulatory system, as indicated by the airflow arrows AF1, AF2 in FIG. 18B.

In some embodiments, the housing 14 can include a plurality of vents to define an air circulation channel. For example, the housing 14 can include inlet vents 150, 151 in the motor housing portion 18 near the sanding pad 100. Moreover, outlet vents 152 may be formed within the motor housing portion 18 within an area of the motor housing portion 18 circumscribing the rotor fan 142. Accordingly, the vents 150, 151, 152 may allow air flow through the eccentric components as shown in FIGS. 18C through 18D to cool the bearings 72, 74 (FIG. 2A and FIG. 3B). The rotor fan 142 can be configured to pull air through the vented torque absorber 38, allowing air flow through the eccentric components, such as the bearing 74, carrier 66, and/or counterweight 73, to cool the bearings 72, 74 (FIG. 2A and FIG. 3B). Some of the vents 150 can be placed directly or substantially near the location of the hottest bearing to provide greatest heat transfer for optimal cooling. In some embodiments, the sander 10 housing 14 can include vents 150 in the handle 16 and/or motor housing 18 to allow air to exit the sander 10 creating circulation throughout the sander 10. The vents 150 can be part of dedicated air channels formed in the housing 14, can be open to the interior of the housing 14 or a combination thereof.

Referring to FIGS. 19 through 20C, in some embodiments, the orbit sander 10 can include an axial flow fan 154 in addition to the rotor fan 142. As shown in FIGS. 20A-20C, the axial flow fan 154 can include an annular hub 154 a and a plurality of blades 154 b that extend radially outward from the annular hub 154 a, without a band interconnecting the outer edges of the blades 154 b. The axial flow fan 154 can be mounted within the housing 14 near, or otherwise proximate to, the working end of the tool. For example, the axial flow fan 154 can be mounted to an outer peripheral surface of an eccentric hub 73 c of the counterweight 73, as shown in FIG. 19 . The axial flow fan 154 can also be situated between the counterweight 73 and the eccentric bearing 74. The axial flow fan 154 can be mounted using any combination of methods, such as being press-fit to the eccentric hub 73 c of the counterweight 73. In this configuration, the axial flow fan 154 can also eccentrically co-rotate with the counterweight 73, while the eccentric carrier 66 remains rotationally fixed to the motor housing portion 18 by the torque absorber 38, to induce an axial airflow around the eccentric carrier 66 to both cool the eccentric carrier 66 and the bearing 74.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.

Various features of the invention are set forth in the following claims. 

1. An orbital sander comprising: a housing; a drive unit within the housing, the drive unit including an electric motor defining a rotational axis, a drive shaft configured to receive torque from the electric motor for rotating the drive shaft about the rotational axis, the drive shaft having an eccentric portion configured to orbit about the rotational axis; a sanding pad coupled to the eccentric portion of the drive shaft for orbital motion about the rotational axis; a handle portion extending from the housing at an oblique angle greater than 90 degrees relative to the rotational axis; and a battery pack coupled to the handle for providing power to the electric motor.
 2. The orbital sander of claim 1, further comprising: an electronic controller; a trigger switch configured to provide an input signal to the controller to activate and deactivate the motor in response to actuation of the trigger switch; and a variable speed control configured to provide a speed parameter to the controller to limit an operating speed of the motor.
 3. The orbital sander of claim 2, further comprising a lock-on button configured to maintain the trigger switch in an actuated state.
 4. The orbital sander of claim 1, further comprising: an electronic controller; and a trigger switch configured to provide an input signal to the controller to activate and deactivate the motor in response to actuation of the trigger switch, wherein the trigger switch includes a trigger travel of 1.5 times a width of a user's finger.
 5. The orbital sander of claim 1, wherein an overall height of the motor housing is 110 millimeters to 120 millimeters as measured between an upper plane passing through an uppermost portion of the orbital sander and a lower plane passing through lowermost portion of the orbital sander.
 6. The orbital sander of claim 2, wherein a distance between the trigger switch and a work surface measured between a trigger plane and a work surface plane is 40 millimeters to 60 millimeters.
 7. The orbital sander of claim 1, wherein a handle angle between a longitudinal axis of the handle portion and a longitudinal axis of the motor housing is ninety-five degrees (95°).
 8. The orbital sander of claim 1, wherein an overall length of the orbital sander measured between a foremost plane of the orbital sander and an interface plane at an interface of the handle portion and the battery pack is 220 millimeters to 240 millimeters.
 9. The orbital sander of claim 1, further comprising a work light coupled to the housing and configured to project light onto a work surface and at least a portion of the sanding pad.
 10. The orbital sander of claim 9, wherein the housing comprises a motor housing portion in which the electric motor is located, and wherein the work light is mounted near a top, front of the motor housing portion.
 11. The orbital sander of claim 10, wherein the handle portion extends from a rear of the motor housing portion.
 12. The orbital sander of claim 10, wherein the work light forms a beam angle with respect to a rotational axis of the electric motor, and wherein the beam angle is thirty-five degrees (35°).
 13. The orbital sander of claim 9, wherein the sanding pad includes a sanding pad surface area, and wherein the work light projects an illumination area that is at least six times greater than the sanding pad surface area.
 14. The orbital sander of claim 1, wherein the housing includes a motor housing portion in which the electric motor is located and a handle portion extending from the motor housing portion, wherein the electric motor includes a stator, and wherein the orbital sander further comprises one or more battery terminals situated within the handle portion and located between respective planes coinciding with opposite ends of the stator.
 15. The orbital sander of claim 14, wherein the planes are parallel to the sanding pad.
 16. The orbital sander of claim 15, wherein the planes are parallel to a longitudinal axis of the handle portion.
 17. The orbital sander of claim 1, wherein the housing includes a motor housing portion in which the electric motor is located and a handle portion extending from the motor housing portion, and wherein the orbital sander further comprises an electronic controller within the handle portion and oriented at an oblique angle relative to a longitudinal axis of the handle portion.
 18. The orbital sander of claim 17, wherein the electronic controller has an oblong shape.
 19. The orbital sander of claim 17, wherein the controller is positioned within the handle portion at an angle of thirty-five degrees (35°) with respect to the rotational axis of the motor. 20-48. (canceled) 